Premium shelf presence and full recyclability are briefs that often pull in opposite directions. For The Chocolate Garden of Ireland, we resolved both.

The Job

A two component packaging system: printed outer sleeve and inner carton, both on 260gsm Cyber Premium board. Fully kerbside recyclable thanks to applying a flood gloss finish from our UV coating system instead of non-recyclable lamination.

Print

Both components printed in Pantone 7527C, chosen to lock in the brand’s signature neutral tone and eliminate the colour drift that comes with building this shade in CMYK. Consistency between sleeve and carton was non-negotiable.

Finishing

Lamination replaced entirely with a flood gloss varnish, delivering the luxury finish the brand demands while keeping the pack sustainable. Gold foil applied directly over the varnish, with dwell time, temperature, and pressure controlled for clean definition on the high-gloss surface.

Structure

The inner carton features a twice-glued base for rigidity under product weight across distribution and retail handling. Both components die-cut using newly produced cutting forms, with crease geometry specified to prevent surface cracking and ensure clean hand assembly.

The Result

A recyclable, shelf-ready packaging solution that proves sustainability and premium print quality are not a trade-off.